Shoe with Composite Upper and Foam Element and Method of Making Same

ABSTRACT

A bonded mesh composite panel can be used to form a three-dimensional upper shell that includes extensions used for double-lasting and/or to otherwise provide a shelf to support foam padding. The foam padding may be, e.g., a foam midsole. The extensions of the upper shell may be located in a lower portion of the shell and may be bonded to the foam midsole in a heel, midfoot and/or forefoot regions.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.13/029,502, titled “Shoe with Composite Upper and Foam Element andMethod of Making Same” and filed Feb. 17, 2011, which application is acontinuation-in-part of U.S. patent application Ser. No. 12/603,494,titled “Composite Shoe Upper and Method of Making Same” and filed Oct.21, 2009, and of U.S. patent application Ser. No. 12/603,498, alsotitled “Composite Shoe Upper and Method of Making Same” and filed Oct.21, 2009. Application Ser. No. 13/029,502, application Ser. No.12/603,494 and application Ser. No. 12/603,498 are incorporated byreference herein.

BACKGROUND

The design of many types of footwear is often driven by conflictingconsiderations. As but one example, it is normally desirable for anathletic shoe to have a construction that supports and protects awearer's foot during a particular athletic endeavor. However,“breathability” is also a desirable quality for many types of athleticshoes. Specifically, air flow from the outside to a shoe interior canhelp relieve the effects of heat and perspiration that typically buildup around a foot during sporting activities. Unfortunately, manymaterials that provide good support and foot protection can block airand moisture flow. Conversely, many materials that facilitate air andmoisture flow provide little support or protection to the wearer's foot.

One solution is to fabricate a shoe in which some portions are formedfrom supportive/protective materials and some portions are formed frombreathable materials. However, this can increase the complexity of thefabrication process and increase cost. Moreover, footwear design(including athletic footwear design) is also driven by aesthetics. Acomplex production process developed to fabricate a complex shoe canpotentially limit a manufacturer's ability to vary that shoe's design toachieve different aesthetic effects.

SUMMARY

This Summary is provided to introduce a selection of concepts in asimplified form that are further described below in the DetailedDescription. This Summary is not intended to identify key features oressential features of the invention.

In at least some embodiments, a shoe has an upper that includes a bondedmesh composite panel. The panel includes a substrate layer formed fromsynthetic leather or another material chosen to provide support andprotection to the foot of a wearer, but that can include ventilationopenings. The panel further includes a mesh layer that is bonded to thesubstrate layer and spans one or more of the ventilation openings. Oneor more panels of thermoplastic polyurethane (TPU) or other desiredmaterial can also be included in certain regions so as to create skinlayers that provide abrasion protection for the mesh layer and/or toachieve different aesthetic effects.

A bonded mesh composite panel for an upper is in some embodimentsfabricated by first arranging panels of substrate, mesh and skin layermaterials into an assembly corresponding to the locations of thosepanels in a completed upper. The assembly may also include separatelayers of hot melt bonding material interposed between the substrate,mesh and skin layers, and/or a bonding material may be a component of asubstrate, mesh and/or skin layer material. The assembly is then pressedat an elevated temperature so as to melt the bonding material and theskin layers and bond the elements together. Before the pressed assemblycompletely cools, it is pressed a second time in an unheated press. Aheat-conductive compressible pad can be used in the pressing process tocreate a surface effect in the skin layers that reveals a pattern of anunderlying mesh layer.

In some embodiments, a bonded mesh composite panel is used to form athree-dimensional upper shell that includes extensions used fordouble-lasting and/or to otherwise provide a shelf to support foampadding. The foam padding may be, e.g., a foam midsole. The extensionsof the upper shell may be located in a lower portion of the shell andmay be bonded to the foam midsole in a heel, midfoot and/or forefootregions.

BRIEF DESCRIPTION OF THE DRAWINGS

Some embodiments are illustrated by way of example, and not by way oflimitation, in the figures of the accompanying drawings and in whichlike reference numerals refer to similar elements.

FIGS. 1A and 1B are, respectively, lateral and medial views of a shoeaccording to some embodiments.

FIG. 1C is an enlarged view of the area indicated in FIG. 1A showing anaspect of the mesh composite in the embodiment of FIGS. 1A and 1B.

FIG. 2 is a partially schematic diagram showing creation of a multilayermesh composite according to some embodiments.

FIG. 3 is a partially schematic cross-sectional view from the locationindicated in FIG. 1A showing the structure of a mesh composite accordingto some embodiments.

FIGS. 4A1 through 4K show operations in a process, according to at leastsome embodiments, to fabricate a unibody upper panel for the shoe ofFIGS. 1A and 1B.

FIGS. 5A through 5G show additional operations in a process, accordingto at least some embodiments, to fabricate an upper for the shoe ofFIGS. 1A and 1B.

FIGS. 6A and 6B show examples of composite upper portions, according tosome additional embodiments, that include an additional layer forreinforcement, support and/or padding.

FIG. 7 shows a toe cap extension in a shoe according to someembodiments.

FIG. 8 shows a layer of skin material used to reinforce a transitionfrom a mesh composite portion of a shell to another portion according tosome embodiments.

FIGS. 9A through 9C show an assembly jig that can be used in fabricationmethods according to some embodiments.

FIGS. 10A through 10E show assembly of panel elements for a unibodyupper shell according to another embodiment.

FIG. 11 shows a bonded composite panel formed from the panels assembledin FIGS. 10A through 10E.

FIG. 12 shows the bonded composite panel of FIG. 11 after trimming.

FIG. 13 shows an inner face of the trimmed, bonded composite panel ofFIG. 12.

FIG. 14 shows a three-dimensional upper shell formed from the trimmed,bonded composite panel of FIG. 12 and placed onto a last.

FIGS. 15A and 15B show attachment of the three-dimensional upper shellfrom FIG. 14 to a foam midsole.

FIG. 16 shows a completed shoe that includes the upper shell andattached foam midsole from FIG. 15B.

DETAILED DESCRIPTION

At least some embodiments include an athletic shoe or other type offootwear in which an upper has a panel formed from a bonded meshcomposite. The mesh composite includes an inner substrate layer thatprovides support and protection in appropriate regions based onactivities for which the shoe is intended. The substrate layer can alsoinclude one or more openings for ventilation, weight reduction or otherpurposes. The mesh composite further includes a mesh layer that isbonded to the substrate layer and located on the outer side of thesubstrate in the finished shoe. This construction offers severaladvantages. For example, the mesh can reinforce the substrate and helpretain individual portions of the substrate in a desired arrangement,thereby permitting larger ventilation holes in the substrate. Moreover,covering those ventilation holes and surrounding substrate regions witha mesh can avoid edges that might separate as the shoe wears. A “skin”layer may cover the mesh layer in one or more areas to provideadditional durability and/or for decorative purposes. In someembodiments, substantially all of the upper is formed from a meshcomposite panel that extends around the heel counter region. In otherembodiments, the upper may have a mesh composite panel in a frontportion that is bonded or otherwise attached to a separate panel thatforms a rear portion of the upper.

Definitions

To assist and clarify subsequent description of various embodiments,various terms are defined herein. Unless otherwise indicated, thefollowing definitions apply throughout this specification (including theclaims). The “interior” of a shoe refers to space that is occupied by awearer's foot when the shoe is worn. The “inner side” of a panel orother shoe element refers to the face of that panel or element that is(or will be) oriented toward the shoe interior in a completed shoe. The“outer side” of an element refers to the face of that element that is(or will be) oriented away from the shoe interior in the completed shoe.In some cases, the inner side of an element may have other elementsbetween that inner side and the interior in the completed shoe.Similarly, an outer side of an element may have other elements betweenthat outer side and the space external to the completed shoe.

A “bonded” composite element is an element that includes substituentelements (e.g., panels of textile or other materials) that are bonded toone another. Bonding includes bonding through use of glue or otheradhesives, through melting and subsequent solidification of a bondingmaterial, and/or through melting and subsequent solidification of asubstituent element, but excludes stitching, stapling or similar typesof mechanical attachment. Although a bonded composite element mayinclude stitching or other types of mechanical attachment (e.g., toattach the bonded composite element to another element, to shape thebonded composite element), the bonded composite does not rely on thatstitching or other mechanical attachment to structurally connect thesubstituent elements of the bonded composite.

Certain regions of an upper are defined by reference to the anatomicalstructures of a human foot wearing a shoe that is properly sized forthat foot. One or more of the below-defined regions may overlap. The“forefoot” region of an upper is the portion of the upper that willgenerally cover the metatarsal and phalangeal bones of the wearer'sfoot, and which will extend beyond the wearer's toes to the frontmostportion of the upper. The “midfoot” region of an upper is the portion ofthe upper that will generally cover the cuboid, navicular, medialcuneiform, intermediate cuneiform and lateral cuneiform bones of thewearer's foot. The “hindfoot” region of an upper extends from themidfoot region to the rearmost portion of the upper and covers thewearer heel. The hindfoot region covers the sides of the calcaneous boneof a wearer and may, depending on a particular shoe configuration, coversome or all of the wearer's talus bone (ankle).

The top forefoot and top midfoot regions of an upper will generallycover the upper surfaces of a wearer's forefoot and midfoot bonesdescribed above. The toe of the upper is the portion that will generallycover the tops and fronts of the toes and that extends from the topforefoot region to the lowest edge of the upper in the direction of thesole. The lateral forefoot region extends between the top forefoot andthe lowest edge of the upper in the direction of the sole and betweenthe toe and lateral midfoot regions. The lateral midfoot region extendsbetween the top midfoot region and the lowest edge of the upper in thedirection of the sole and between the lateral forefoot and hindfootregions. In a similar manner, the medial forefoot region extends betweenthe top forefoot region and the lowest edge of the upper in thedirection of the sole and between the toe and medial midfoot regions,the medial midfoot region extends between the top midfoot region and thelowest edge of the upper in the direction of the sole and between themedial forefoot and hindfoot regions. The topfoot region includes thetop forefoot and top midfoot regions. The lateral side region includesthe lateral forefoot and lateral midfoot regions. The medial side regionincludes the medial forefoot and medial midfoot regions.

Shoe with Mesh Composite Upper Panel

FIG. 1A is lateral view of a shoe 10 according to at least someembodiments. FIG. 1B is a medial view of shoe 10. In the embodiment ofFIGS. 1A and 1B, the upper 11 of shoe 10 includes a bonded meshcomposite panel 16 and a foxing panel 17. Additional details of meshcomposite panel 16 and its construction, as well the attachment of meshcomposite panel 16 to foxing panel 17, are provided below in connectionwith FIGS. 1C and 4A1-4K.

In the embodiment of shoe 10, mesh composite panel 16 generally coversthe toe region, the top, lateral and medial forefoot regions, the top,lateral and medial midfoot regions, and portions of the hindfoot region.Rear portion 17 covers the remainder of the hindfoot region. Asexplained in more detail below, shoe 10 of FIGS. 1A and 1B is merely oneexample of footwear according to various embodiments. In otherembodiments, a mesh composite front portion of an upper panel may bejoined to a non-mesh-composite rear portion at different locationsand/or along joints having different configurations. In still otherembodiments (e.g., an embodiment such as is described in connection withFIGS. 10A-16), an entire upper shell is formed from a mesh compositethat includes a contiguous substrate element that completely surrounds awearer foot in a completed shoe

FIG. 1C is an enlarged view of the area indicated in FIG. 1A showing thedetails of a portion of mesh composite panel 16 in the embodiment ofshoe 10. A layer 28 of mesh material is bonded to a layer 27 ofsubstrate material in a manner described below. For illustrativepurposes, a portion of the mesh layer 28 below broken line 30 has beenremoved in FIG. 1C to further expose substrate layer 27. For convenienceand to avoid obscuring the drawings with excessive detail, the meshmaterial of layer 28 (and of mesh layers in other embodiments) is shownin the various drawing figures as a simple and relatively course gridpattern with a diagonal orientation. Actual materials used for meshlayer 28 (or for mesh layers in other embodiments), examples of whichare provided below, may have a more complex and/or finer weavestructure. A panel 36 a of skin material is in turn bonded to mesh layer28 and to substrate layer 27 to form a skin layer. As is also discussedin more detail below, the layer of skin material conforms to the meshmaterial of layer 28 so as to reveal a surface texture having a contourcorresponding to that of the mesh material. For simplicity, a view ofthis conformance perpendicular to a skin layer is represented in thedrawings as a partially broken version of the grid pattern used for meshlayer 28.

Returning to FIGS. 1A and 1B, the substrate material of layer 27 extendsacross all of mesh composite panel 16 except for a tongue opening 26,lateral ventilation holes 31 and 32, medial ventilation hole 33, and topforefoot ventilation hole 34. Other embodiments have an inner substratematerial layer that includes more or fewer holes, and/or holes ofdifferent shapes and/or in different locations. As is further explainedbelow in connection with FIGS. 4A1-4K, the mesh material of layer 28 isbonded to substrate layer 27 over most of panel 16 in the embodiment ofFIGS. 1A and 1B, although this may not be the case in other embodiments.

The embodiment of FIGS. 1A and 1B also includes skin layers formed bypanels 36 a, 36 b, 36 c and 36 d. The skin material of panels 36 b and36 c similarly conforms to the mesh material of layer 28 so as to reveala surface texture corresponding to the mesh. The mesh materialunderlying panel 36 d is compressed so as to provide a smooth texture onthe external surface of panel 36 d, as is also described more fullybelow.

Because mesh layer 28 is directly bonded to substrate layer 27, thecombined strength of the mesh and substrate materials obviates the needfor another material on the outside surface of upper 11 to providetensile strength. This permits upper 11 to be much lighter than ispossible using various conventional shoe construction techniques. Panelsof skin material (which are relatively lightweight) can be included incertain areas of an upper where abrasion protection is helpful.

Ventilation holes 31, 32, 33 and 34 in substrate layer 27 allow air toflow through perforations of the mesh material of layer 28. This flowhelps to cool and dry the foot of a wearer of shoe 10. In someembodiments, there are no additional material layers separatingsubstrate layer 27 and the foot of a wearer (or the socked foot of awearer) in the regions around one or more of holes 31, 32, 33 and 34,and air can directly reach the interior of shoe 10. In otherembodiments, upper 11 of shoe 10 may include an additional lining (e.g.,a “bootie”) between substrate layer 27 and a wearer's foot. In suchembodiments, air cannot directly reach the wearer's foot through holes31, 32, 33 and 34, but ventilation is still improved relative to manyconventional constructions, as materials used for a bootie or otherliner are typically porous and significantly more breathable thanmaterials used for substrate layer 27.

The number, size and location of ventilation holes will vary indifferent embodiments. In some embodiments, an upper may includeventilation holes as small as (or smaller than) 2 mm in diameter, whilein other embodiments, the ventilation holes may be quite large and covera substantial portion of the upper. In some embodiments, minimum spacingbetween some ventilation holes can be based on the minimum area neededto effectively bond the mesh and substrate layer materials used for aparticular embodiment.

The material of skin layer panels 36 a, 36 b, 36 c and 36 d providesabrasion protection for mesh layer 28. A skin material panel can also beadded for decorative purposes. For example, skin material elements caninclude one or more additional elements such as element 36 d in theshape of a logo or other identifier of the manufacturer of shoe 10.Although much of skin layer panels 36 a-36 d are overlaid on the meshmaterial of layer 28, some portions of skin layer panels are directlybonded to substrate layer 27 without an interposing layer of meshmaterial. For example, and as described in more detail below inconnection with FIGS. 4A1-4K, skin layer panels 36 a-36 c cover someportions of substrate layer 27 over which mesh layer 28 does not extend.Moreover, and as also described in more detail below, a portion of skinlayer panel 36 a overlays (and is bonded to) foxing panel 17. In somecases, an interposing mesh layer is omitted for structural purposes. Aninterposing mesh layer could also be omitted for decorative reasons.

Shoe 10 includes a foamed ankle collar 141, a heel counter (not shown)and a tongue 41. Tongue 41 may be stitched or otherwise bonded to theinside of upper 11. Attachment of collar 141 is described below. Upper11 may be bonded to a midsole 42 in any of various manners. In someembodiments, upper 11 is slip lasted and attached to a Strobel layer,with that Strobel layer then bonded to an upper face of midsole 42.Other types of constructions are used in other embodiments to attachupper 11 to a midsole or other sole component. One example of such aconstruction is discussed below in connection with FIGS. 15A and 15B.

As can also be seen in FIGS. 1A and 1B, the pattern of the mesh materialof layer 28 (represented in FIGS. 1A through 1C as a coarse diagonalgrid) is exposed over a substantial portion of composite panel 16. Inparticular, that mesh material is directly visible in regions of panel16 not covered by one of skin layer panels 36 a-36 d. In much of theareas covered by skin layer panels, however, the pattern of theunderlying mesh material is still visible because of the skin layerconformance to that mesh. In some embodiments, the pattern of the meshmaterial in the mesh layer is visible over a substantial portion (oreven most) of the surface of the mesh composite panel in the finishedshoe. This pattern may be visible directly in areas where the mesh isexposed (e.g., over openings 31, 32, 33 and 34 and in the regionssurrounding those openings) or as a contour of a skin layer panel (e.g.,the portion of panel 36 a shown in FIG. 1C). In some embodiments, thepercentage of exposed mesh will depend on the purpose of the shoe.

Shoe 10 of FIGS. 1A and 1B is merely one example of a shoe having amultilayer bonded mesh composite upper panel according to certainembodiments. Additional embodiments include other styles of shoes, shoeswith different types of midsole/outsole combinations, shoes withdifferent patterns of substrate material holes, and shoes with differentskin material configurations. Still other embodiments include shoes withadditional layers and/or layers of additional types of materials.

FIG. 2 is a partially schematic diagram showing creation of multilayerbonded mesh composite panel 16. Substrate layer 27, mesh layer 28, andskin layer panels 36 a-36 d are assembled in a manner described below.For purposes of explanation, substrate layer 27 is shown incross-sectional views with fine stippling, skin panels are shown withcoarse stippling, and mesh layer 28 is shown with cross-hatching. Theopen areas between the cross-hatched portions of mesh layer 28correspond to mesh material openings. Interposed between mesh layer 28and substrate layer 27 is a layer 39 of hot melt bonding material (shownwith small black dots). Another layer 40 of hot melt bonding material isplaced between mesh layer 28 and skin layer panels 36 a-36 d. After thelayers are tacked together, the assembly is covered with a heatconductive silicone pad 44 and put into a heated press 45, with the skinmaterial panels facing silicone pad 44. Heat and pressure are thenapplied to activate the bonding material and to cause the skin materialto reach its melting point. As a result, the bonding material in layers39 and 40 bonds substrate layer 27 to mesh layer 28 and mesh layer 28 toskin layer panels 36 a-36 d, the skin material of panels 36 a-36 dbegins to conform (and further bond) to the mesh material of layer 28,and the various layers bond to become a one-piece panel. After thatheated pressing, the layers are then pressed again in a separate coolpress (not shown). Additional details of the pressing operations areprovided below.

In some embodiments, a separate panel of hot melt bonding material maynot be placed between a skin layer panel and a mesh or substrate layerpanel. Instead, the skin layer panel is bonded to the other layer(s)solely through the melting of the skin layer panel so as to fuse theskin layer to one or more other layers. Similarly, inserting a separatepanel of hot melt bonding material between a substrate material paneland a mesh material panel is unnecessary in some embodiments. In certainembodiments, for example, a substrate layer 27 may comprise a laminatethat includes a first material layer (e.g., artificial leather) and asecond material layer (e.g., thermoplastic polyurethane) prelaminated toa face of the first material layer by the substrate materialmanufacturer. Panels of that two layer substrate material can then becut to shape by a shoe manufacturer and used as substrate layer 27. Insuch an embodiment, the second material layer would be oriented to facemesh layer 28 and would melt during pressing so as to fuse to mesh layer28 (and to the skin layer(s)), and the separate layer of bondingmaterial 39 could be omitted. Indeed, some embodiments may not requireany separate bonding material layers, and could rely on melting of theskin and/or substrate layers themselves to achieve bonding. As anotheralternative, large sections of mesh, substrate or skin material couldhave a separate hot melt bonding material (e.g., such as would be usedfor layer 39 or 40) pre-applied (e.g., by the material supplier or in apreprocessing step by a shoe manufacturer) prior to cutting ofindividual upper panels from the large material sections. Combinationsof these techniques could also be used.

FIG. 3 is a partially schematic cross-sectional view from the locationindicated in FIG. 1A showing the structure of mesh composite panel 16after hot and cold pressings. For purposes of illustration, threedifferent regions are labeled in FIG. 3. Region A corresponds to thelocation of the mesh composite panel 16 where hole 32 in substrate layer27 is located. Because no other material layers are present in region A,the mesh material of layer 28 is not bonded to another material in thisregion. If upper 11 includes a liner (i.e., on the inner side ofsubstrate layer 27), such as is shown in FIG. 3 with a broken line, themesh material of layer 28 is in at least some embodiments not bonded tothat liner in the region of holes in substrate layer 27. In someembodiments, however, a liner may be stitched to mesh layer 28 and/orother portions of shell 11 in some locations and/or bonded to the insidesurface of substrate layer 27 at some locations.

Region B in FIG. 3 corresponds to a location of mesh composite panel 16where no skin material panel is present. Region C corresponds to alocation where substrate layer 27, mesh layer 28 and skin layer panelelement 36 a are present. In regions B and C, and throughout meshcomposite panel 16, the substrate material of layer 27 and the meshmaterial of layer 28 are bonded together at all surfaces where those twomaterials are in contact. Similarly, skin layer element 36 a and thesubstrate material of layer 27 are bonded together at all surfaces wherethose materials contact, as are panel 36 a and the mesh material oflayer 28. Other skin material panels are similarly bonded to thesubstrate material of layer 27 and the mesh material of layer 28.Bonding substrate and mesh materials, and/or skin materials, effectivelyfuses the materials together so as to create a material that is strongerthan the individual components.

As also seen in region C, the skin material of panel 36 a conforms tothe mesh material of layer 28 so that a contour of the mesh materialpattern is revealed through panel 36 a. Other skin material panels thatoverlay mesh layer 28 similarly conform to the mesh material. In thismanner, upper 11 can have a more continuous appearance than mightotherwise be possible. By providing layers of skin material that have atexture revealing an underlying mesh material, a potential purchaser ofshoe 10 is also made aware of the structure of shoe 10. Moreover, it isbelieved that the conformal nature of the contact between a skinmaterial panel and underlying mesh and substrate layer materials helpsto increase the bonded surface areas and overall material strength.

As indicated above, the substrate material of layer 27 provides supportand protection for the foot of a wearer of shoe 10. In at least someembodiments, the substrate material is (or includes) a synthetic leatheror another material that is sufficiently durable to protect a foot inregions where the upper is likely to contact external objects and/orwhere foot support is needed, but sufficiently flexible to providecomfort.

Many different substrate materials can be used. In some embodiments,substrate materials are selected so as to provide support for thelamination package (i.e., the stack of substrate, mesh and othermaterials assembled to create an upper) and to adequately bond to themesh material. To achieve such goals, substrate materials can be chosenso as to have limited stretch, to bond well and be chemically compatiblewith TPU hot melt, to have a continuous (i.e., non-mesh) surface so asto provide more bonding surface area, and to be cuttable with cleanedges in mass production. Table 1 lists examples of substrate materialsthat can be used in at least some embodiments; other materials couldalso be used.

TABLE 1 Material Type/Description Example Commercially-Available ProductEPM synthetic suede CLARINO TIRRENINA NUBUCK 0.5-1.0 mm thick (KurarayAmerica, Inc., New York, NY) regular density synthetic SOFT-R 1.1 mm(Nan Ya Plastics leather Corporation, Taiwan) microfiber syntheticleather THUNDER II, 1.4 mm (Nan Ya Plastics Corporation, Taiwan) EPMsynthetic leather with KANGA ENV 1.3 mm or 1.5 mm (Nan Ya 50% rePET inhigh density Plastics Corporation, Taiwan) substrate buffed high densityKITE BUFF 0.9 mm (Daewoo International synthetic leather Corporation,Pusan, Korea) poly/nylon nonwoven EVO80 WS (Freudenberg & Co., Weinheim,Germany) perfed microfiber polyester LJ-M11K (Gold Long JohnInternational Co, textile Taiwan) polyester textile package POLYPAG PLUSMULTI (You Young Co., Ltd., Korea) polyester textile package JEKYLL PLUSMULTI (You Young Co., Ltd., Korea) TPU coated synthetic A806/A807 (ChaeiHsin Enterprise Co., leather Ltd., Taiwan)

The mesh material of layer 28 reinforces upper 11 by augmenting thestrength of the substrate material where the two materials are bonded,thereby allowing use of thinner substrate material elements.Incorporation of mesh material into an upper further allows eliminationof substrate material in areas where the full protection and support ofthe substrate material is not as important, thus permitting furtherreduction in substrate material and overall shoe weight. The meshmaterial of layer 28 also allows air to flow through openings insubstrate layer 27 to help cool and dry the foot of a wearer.

In at least some embodiments, the mesh material of layer 28 is a singlelayer warped knit with an open structure (or other type of wovenmaterial) and is formed from nylon, polyester, nylon/polyester blends,recycled polyethylene terephthalate (rePET), or other material. Incertain embodiments, the mesh material has more than 50% open area(e.g., more than 50% of the material surface area comprises open spacethrough which air can freely flow from one side to the other). In someembodiments, SPANDEX (or other stretchable meshes) and spacer meshes(meshes with filler yarn) are undesirable. Table 2 lists examples of themesh material in at least some embodiments; other materials could alsobe used.

TABLE 2 Material Type/Description Example Commercially-Available Product100% PET E-minicell mesh 420D single mesh (Daewoo InternationalCorporation, Pusan, Korea) mesh BULLHEAD mesh (Formosa Ting Sho Co.,Ltd., Taiwan) 35% rePET mesh TENOR mesh (Joonang Textile Co., Ltd.,Korea) 38.6% rePET mesh AIR TING mesh (Mogae Textile Co., Ltd., Busan,Korea) 34% nylon 200D/84F, 66% TLE8B001 DUONET (Tiong Liong polyester300D/168F Industrial Co., Ltd., Taiwan) 32% polyester 100D/36F, TLD9B018BLOCKBUSTER (Tiong Liong 68% polyester 300D/168F Industrial Co., Ltd.,Taiwan) 50% rePET mesh MATRIX mesh (You Young Co., Ltd., Korea) 30%rePET mesh MONO RIB mesh (Dong Jin International Corporation, DaeGu,Korea) 30% rePET mesh thermoplastic mesh 6 (Duck San Co., Korea) 30%rePET mesh Egg mesh (You Young Co., Ltd., Korea) Love Look Formosa TingSho Co., Ltd., Taiwan

The skin material for panels 36 a-36 d reinforces the mesh and substratematerials, protects the mesh material layer in certain areas, and/orprovides a decorative surface on upper 11. In at least some embodiments,the skin material is a thermoplastic polyurethane (TPU) or otherappropriate material. In certain embodiments, the skin material is amultilayer material having an outer heat-resistant layer for abrasionresistance and an inner layer for hot melt bonding. For example, theouter layer can be thermoset polyurethane (PU) or a TPU with a high melttemperature, and the inner layer can be a TPU having a lower melttemperature suitable for hot melt bonding and production temperatures.Table 3 lists examples of materials that can be used for the skinmaterial in at least some embodiments; other materials could also beused.

TABLE 3 Example Material Type/Description Commercially-Available Product0.4 mm thermoset UT900 (San Fang Chemical Industry polyurethane (PU)film Co., Ltd., Taiwan) TPU film FW film (Daewon Chemical Company, Ltd.,Korea) Dual (H/L) TPU film having FD26K series (Ding Zing Chemical 0.1mm high melting temp. Products Co., Ltd., Taiwan) aliphatic film layerand 0.2 mm low melting temp. aromatic polyester film FS8080 layer 0.3 mmfilm having 0.1 mm SKN300 (Teijin, Okahata, Japan) PU layer and 0.2 mmTPU hot melt layer 0.35 mm PU coated hot melt HH Million AB (DaewooInternational, film Busan, Korea)

In at least some embodiments, and as shown schematically in FIG. 2,various layers of material are bonded by interposing a separate layer ofhot melt bonding material between those materials and then activatingthat bonding material in a heated press. In at least some embodiments,the hot melt bonding material generally has a pre-activation consistencyof a fine fibrous mat that is similar in thickness (and appearance) to afine spider web. This allows the activated bonding material to fullycover contacting surfaces without excess buildup of hardened bondingmaterial. In some embodiments, hot melt bonding material mats can belaid onto sheets of mesh and skin material, with the sheets then rolledand provided to a shoe manufacturer. The manufacturer can then unrollthe mesh and bonding material combination (or the skin and bondingmaterial combination) and cut appropriate shapes for an upper in asingle die-cutting operation.

In at least some embodiments, a TPU hot melt bonding material could havea melt temperature between 80° C. and approximately 120° C. and bepolyester-based. Table 4 lists examples of hot melt bonding materialsthat can be used in at least some embodiments; other hot melt bondingmaterials could also be used.

TABLE 4 Material Type/Description Example Commercially-Available Producthot melt film F1500 (Duck San Co. Ltd, Seoul, Korea)polyurethane/polyester base FS8080 (Ding Zing Chemical Products Co., hotmelt film Ltd., Taiwan) hot melt film FS4252X3 (Ding Zing ChemicalProducts Co., Ltd., Taiwan) hot melt film NASA 600 (Sambu, Korea) hotmelt film Meltlace Web 100E (Dongsung Adhesives division Henkel AG & Co.KGaA) polyether film (.05 mm to FT1029 (Ding Zing Chemical Products Co.,2 mm thickness) Ltd., Taiwan)The final material in Table 4 (polyether film) may be desirable, e.g.,in certain embodiments in which high humidity is a concern.

Fabrication of an Upper Shell Having a Mesh Composite Portion

According to at least some embodiments, a bonded mesh composite panel ofan upper is created by assembling individual panels of material for thevarious layers in a flat configuration. If the upper is to includeadditional portions (e.g., a rear portion such as panel 17 of shoe 10),additional material elements can be included as part of the assemblyprocess. The panels and other elements are assembled so as to have anarrangement in which the relative locations of the panels and elementscorrespond to the locations those panels and elements will have in thecompleted shoe. After assembling the individual panels and/or otherelements into the proper arrangement and tacking the assembly at severallocations, the assembly undergoes a series of pressing operations tobond the assembled elements. These operations create a flat, one-pieceunibody upper shell that can contain many or all elements to be includedin the finished upper. Edges of the unibody upper shell can then bejoined to create a three-dimensional upper body ready for furtherfinishing and attachment to a midsole.

FIGS. 4A1 through 4K show a process, according to at least someembodiments, to fabricate the mesh composite panel 16 for shoe 10 ofFIGS. 1A and 1B. In step 1 shown in FIGS. 4A1 and 4A2, foxing panel 17is attached to an assembly jig 100. FIG. 4A2 is a side view of jig 100and foxing panel 17, from the position noted in FIG. 4A1, that isincluded to further show the use of jig 100. Each of pins 101 a-101 q injig 100 extends upward and is used to position one or more upperelements. For example, and as shown for panel 17, pins 101 a, 101 b and101 e correspond to holes 102 a, 102 b and 102 e in foxing panel 17.Panel 17 is positioned on jig 100 by respectively placing holes 102 a,102 b and 102 e over pins 101 a, 101 b and 101 e and pushing panel 17onto jig 100. The side of foxing panel 17 facing upward at thecompletion of step 1 will face outward and away from the interior of acompleted shoe 10. Hole 102 a of panel 17 is in a small extension tab 99that extends away from an edge 98 of panel 17. Extension tab 99 (andsimilar extension tabs on other elements) will be trimmed away during alater stage of fabrication.

Other elements of upper 11 are positioned on jig 100 in a similarmanner. In step 2 (FIG. 4B), for example, a panel 53 of hot melt bondingmaterial is placed adjacent an edge 54 of foxing panel 17. Bondingmaterial panel 53 will be used to bond foxing panel 17 to a panel ofsubstrate material that will become substrate layer 27 of mesh compositepanel 16. In other embodiments, foxing panel 17 can be attached in adifferent manner (e.g., by relying on the melting of a laminated layerof foxing panel 17, by using a brushed-on liquid adhesive) and/or at adifferent stage of constructing an upper shell.

In step 3 (FIG. 4C), a panel of material for substrate layer 27 isattached to assembly jig 100 by pushing holes 104 b through 104 q in thesubstrate material panel over pins 101 b through 101 q, respectively.Holes 104 b-104 d, 104 f and 104 p are contained in extension tabs thatwill be trimmed away in a subsequent fabrication step. As seen in FIG.4C, the panel of layer 27 includes opening 34 that will ultimately belocated in the top forefoot region of upper 11 (see FIGS. 1A and 1B).Also seen in FIG. 4C are openings 31 and 32 that will ultimately belocated laterally on upper 11 (FIG. 1A) and opening 33 that willultimately be located medially on upper 11 (FIG. 1B). In someembodiments, holes 31, 32, 33 and 34 are cut when the substrate layerpanel is die-cut from a larger piece of material. Tongue opening 26(FIGS. 1A and 1B) will be cut after assembly and pressing. In otherembodiments, tongue opening 26 can also be cut from the substratematerial panel when that panel is die cut. The side of the layer 27panel that is exposed at the completion of step 3 will face outward andaway from the interior of a completed shoe 10.

In step 4 (FIG. 4D), eye stay reinforcement 56 is attached to jig 100 bypushing holes 108 g, 108 h, 108 i and 108 o over pins 101 g, 101 h, 101i and 101 o, respectively. Eye stay reinforcement 57 is similarlyattached by pushing holes 109 j, 109 k and 109 l over holes 101 j, 101 kand 101 l, respectively. In at least some embodiments, reinforcements 56and 57 are added to provide reinforced locations for shoe lace eyelets.In other embodiments, eye stay reinforcements may be omitted or may havedifferent configurations. Panels of unactivated hot melt bondingmaterial can also be interposed between reinforcements 56 and 57 andsubstrate layer 27.

Other types of reinforcements can be placed in other areas of a shoeupper in a manner similar to that used for eye stay reinforcements 56and 57. In some embodiments, for example, additional reinforcement couldbe placed over the area of the substrate layer panel that will belocated in the toe region of a completed upper. In another embodiment,reinforcement materials could be placed over the portions of thesubstrate layer panel that will be located at the lateral and medialsides of a completed shoe, with those reinforcement materials formingreinforcing strap attachment points in a finished upper.

In step 5 (FIG. 4E), a panel of mesh material to form layer 28 isattached to jig 100 by pushing holes 119 b, 119 c, 119 d, 119 e, 119 pand 119 q over pins 101 b, 101 c, 101 d, 101 e, 101 p and 101 q,respectively. Holes 119 b-119 d and 119 p are contained in extensiontabs that will be trimmed away in a subsequent fabrication step. Theside of the layer 28 mesh material panel that is exposed at thecompletion of step 5 will face outward and away from the interior of acompleted shoe 10. A layer of unactivated hot melt bonding material isincluded between the mesh layer 28 panel and the substrate layer 27panel. In some embodiments, a roll of the mesh material used for thepanel of layer 28 is received from a vendor with a layer of hot meltbonding material pre-applied to one side. In such embodiments, the meshmaterial panel for layer 28 is placed onto jig 100 with the bondingmaterial side facing down (i.e., toward substrate layer 27). In otherembodiments, a separate layer of hot melt bonding material having thesame shape as the layer 28 mesh material panel is placed over substratelayer 27 at the conclusion of step 1, and only a plain mesh materialpanel is added in step 5. In still other embodiments, a separate panelof hot melt bonding material between panels 27 and 28 is obviatedthrough use of a substrate material having a prelaminated layer formedfrom a meltable material such as TPU.

As seen in FIG. 4E, the mesh layer 28 panel does not completely coverthe substrate layer 27 panel. For example, a region 110 of the substratematerial panel (corresponding to the toe and lateral side forefootregions of an upper in a completed shoe 10) is not overlapped by themesh material panel. In this manner, a smooth surface of upper 11 can beprovided for subsequent bonding to a toe cap or other external feature.A region 111 of the substrate layer 27 panel is similarly not covered bymesh material so as to provide a smoother interface between thesubstrate layer and reinforcements 56 and 57. Unlike material used forskin layers, reinforcements 56 and 57 are formed from a thicker material(e.g., nylon) that will not conform as readily to mesh layer 28 at thetemperatures used in the pressing process. Although region 112 ofsubstrate layer 27 corresponds to a region that will subsequently becovered by skin material panel 36 d in such a manner so as not reveal anunderlying mesh material layer, mesh layer 28 covers region 112 so thatthe added strength of the mesh material can be present in the portion ofupper 11 to which region 112 will correspond in a completed shoe 10.

In step 6 (FIG. 4F), skin material panel 36 c is attached to jig 100 bypushing holes 114 c, 114 d, 114 f, 114 j and 114 p over pins 101 c, 101d, 101 f, 101 j and 101 p, respectively. Holes 114 c, 114 d, 114 f and114 p are contained in extension tabs that will be trimmed away in asubsequent fabrication step. Panel 36 c will form the skin materialcovering, e.g., the toe, medial forefoot and lateral forefoot regions ona completed shoe 10 (see FIGS. 1A and 1B). The side of panel 36 c thatis exposed at the completion of step 6 will face outward and away fromthe interior of a completed shoe 10. In some embodiments, a roll of thematerial used for panel 36 c and/or other skin material panels is alsoreceived from a vendor with a layer of unactivated hot melt bondingmaterial pre-applied to one side. In other embodiments, a separate layerof hot melt bonding material having the same shape as skin materialpanel 36 c is placed between skin material panel 36 c and previouslypositioned layers as part of step 6. In still other embodiments, one ormore skin material panels are bonded to other layers by melting of theskin material during a hot pressing operation (described below) andsubsequent solidification during cooling, and no separate bondingmaterial is interposed between those skin material panels and otherinwardly-located layers. As also seen by comparing FIGS. 4E and 4F, skinmaterial panel 36 c is assembled so as to be located over substratelayer 27 in region 110 where mesh material is not present.

In some embodiments, extra and/or higher strength bonding materialand/or additional adhesives may be included in portions of a compositepanel that will correspond to a toe region and/or to other forwardregions of an upper of a completed shoe. This additional bonding may bedesirable in embodiments where toe portions of an upper may experiencesignificant stresses during various manufacturing operations (e.g., toeforming, lasting).

In step 7 (FIG. 4G), skin material panel 36 b is attached to jig 100 bypushing holes 113 g, 113 h, 113 i, 113 j, 113 k, 113 l, 113 n and 113 oover 101 g, 101 h, 101 i, 101 j, 101 k, 101 l, 101 n and 101 o,respectively. The outer edges of panel 36 b will face away from theinterior of a completed shoe 10, and the remainder of panel 36 b(together with portions of the underlying substrate material panel andmesh material panel) will be removed to create tongue opening 26. Aswith panel 36 c in step 6, panel 36 b is placed onto jig 100 with theouter side facing up, and a layer of hot melt bonding material isinterposed between panel 36 b and underlying elements.

Panel 36 a of skin layer material is placed onto jig 100 in step 8 (FIG.4H) by pushing holes 115 a, 115 b, 115 e, 115 m, 115 n and 115 o overpins 101 a, 101 b, 101 e, 101 m, 101 n and 101 o, respectively. Holes115 a, 115 b and 115 n are contained in extension tabs that will betrimmed away in a subsequent fabrication step. Panel 36 a will form theskin material layer covering portions of the lateral midfoot andhindfoot regions on a completed shoe 10. As with panel 36 c in step 6, alayer of hot melt bonding material can be interposed between panel 36 aand underlying elements. The result at the conclusion of step 8 is apanel assembly 116 of upper elements that will ultimately become anupper shell that includes mesh composite panel 16 bonded to foxing panel17.

In step 9 (FIG. 4I), elements of assembly 116 are tacked together bypartially activating the hot melt bonding material layers in isolatedlocations. This partial activation can be performed in some embodimentsusing high frequency (HF) welding. For purposes of illustration, theresultant tacking is shown schematically in FIG. 4I as a series of dotsdistributed over the surface of the assembled elements that will formmesh composite panel 16. In practice, the actual locations at which heatis applied for tacking purposes may vary. Tack welding in step 9 can beperformed using a handheld heat gun, or by briefly inserting jig 100with assembly 116 into a press having a plate configured to accommodatepins 101 a through 101 q. In at least some such embodiments, the pressconditions for the tacking step will depend on the particular hot meltselected, but will typically be between about 115° C. and about 125° C.,with pressing for approximately 30 to 35 seconds at approximately 2 to 6kg/cm² of surface pressure.

The tacking of step 9 results in a partial bonding so that theindividual elements of assembly 116 will remain in an assembledcondition when assembly 116 is removed from jig 100. In step 10 (FIG.4J), tacked assembly 116 is heat pressed so as to fully bond theindividual elements together. In particular, tacked assembly 116 isremoved from jig 100 and placed onto heat-transferring silicone pad 120.Assembly 116 is turned upside down so that the side facing upward at theconclusion of steps 8 and 9 is positioned to face downward toward pad120. After a sheet of release paper 121 is placed over assembly 116,heated platens 122 and 123 are brought together and pressure applied tocompress assembly 116. For simplicity, only the outer edges of releasepaper 121 are shown in FIG. 4J. In other embodiments, panel assembly 116may be placed so that the inner side is facing lower platen 122, withrelease paper 121 inserted between the inner side of assembly 116 andplaten 122, and with pad 120 between the outer side of assembly 116 andupper platen 123.

In at least some embodiments, silicone pad 120 is first preheated to110° C. prior to the pressing operation of step 10. Typical processparameters for the hot pressing operation of step 10 are upper and lowerpress platen temperatures of 120° C., press pressure of approximately 20kg/cm², and press time of 30 to 40 seconds. However, the processparameters for a particular shoe upper will depend on the combination ofmaterials and on the panel arrangement applicable to that upper. In someembodiments, the press time for step 10 can be determined by assemblingpanels for a particular upper design into a test panel assembly, withthermocouple temperature probes inserted at one or more locations withinthe test panel assembly. The test panel assembly is then pressed between120° C. press platens until the temperature probes indicate that theinternal assembly temperature has reached a desired melting point forthe skin materials in the test panel assembly. If desired, the presstime can be adjusted upward or downward by adjusting the press platentemperature. The desired melting point temperature for a particular skinmaterial can be determined by using differential scanning calorimetry(50° C./min. scan rate) to find the temperature associated with themaximum heat transfer for that skin material. Press pressure can beadjusted upward if there is insufficient bonding between layers in oneor more test panel assemblies or adjusted downward if there is excessive(and undesired) “flattening” of surface features.

After the heated pressing of step 10, assembly 116 is “cold” pressedbetween room temperature press platens to continue to the bondingprocess and to enable melted TPU to set while under pressure so as toimprove bonding. As used herein, “room temperature” is a temperaturebetween approximately 20° C. and approximately 30° C. By cold pressingassembly 116 immediately after the heated pressing of step 10,individual elements are held in contact while the hot melt bondingmaterial and skin layers solidify, thereby preventing materialsrebounding from one another after the initial heated pressing. Without asubsequent cold pressing, for example, a skin layer element in at leastsome embodiments will not conform to an underlying mesh layer so as toshow the mesh pattern on the outer side of the skin layer.

FIG. 4K shows cold pressing in step 11, which immediately follows step10. After assembly 116 is removed from heated press platens 122 and 123(FIG. 4J) and release paper 121 is taken off, assembly 116 is placed onsilicone pad 129 between cold platens 130 and 131. A different siliconepad can be used in step 11 so as to avoid residual heat remaining in pad120 at the completion of step 10. The same face of assembly 116 thatfaced silicone pad 120 in step 10 faces silicone pad 129 in step 11. Inat least some embodiments, platen 130 and/or 131 may include internalwater lines or another mechanism to maintain the platens at a desiredtemperature. Assembly 116 is then pressed between platens 130 and 131.Typical process parameters for the cold pressing operation of step 11are room temperature (e.g., 25° C.) upper and lower press platens, presspressure of approximately 30 kg/cm², and press time of approximately 30seconds.

Heat-conductive silicone pads 120 and 129 used in steps 10 and 11,respectively, are at least partially compressible and conformable to thesurface features of panel assembly 116. This permits compression of thepanel assembly to bond the various layers without overly flattening thesurface features. This also allows formation of a profile, such as isshown in region C of FIG. 3, in which skin material conforms to anunderlying layer of mesh material so as to reveal contours of that meshmaterial. In at least some embodiments, each of silicone pads 120 and129 has a Shore-A hardness of between 15 to 30 and a thermalconductivity of approximately 0.3 Watts. However, pads with differentthermal conductivities can be used by adjusting press platentemperatures to achieve a desired internal temperature in the pressedmaterials.

At the completion of step 11, tacked assembly 116 has been transformedinto a fused unibody shell that includes mesh composite panel 16 andfoxing panel 17. FIG. 5A shows fused unibody upper shell 116 thatresults from the completion of steps 1 through 11 of FIGS. 4A1-4K, andthat is ready for finishing operations. Edges 133, 134 and 135 aremarked in FIG. 5A and will be further discussed below. In step 12 (FIG.5B), tongue opening 26 is cut, extension tabs on the outer edges ofcomposite panel 16 are trimmed away, and lacing eyelets punched. In step13, (FIG. 5C), skin layer element 36 d is applied by hot pressingcombined with HF welding, but without a cold pressing step, so that skinlayer element 36 d will have a different texture than other portions ofupper 10. In particular, a tool (not shown) having the shape of element36 d is applied to unibody upper shell 116 on the location where panel36 d is to be placed. HF welding heat is then applied through that toolto flatten the region of the mesh material in layer 28 under the tool.Element 36 d is then placed in the flattened region with an interposedlayer of hot melt bonding material and HF welded in place using aheating element (e.g., formed from copper, brass, aluminum or otherconductive material) in the shape of the desired melt pattern at atemperature, pressure and time appropriate for the materials in use. Insome embodiments, element 36 d may be in the shape of a logo or otherindicia that is associated with a manufacturer of the shoe, and adifferent texture for element 36 d may be desired to offset the logofrom other portions of the shoe upper or for some other aestheticpurpose. In embodiments where a different texture for element 36 d isnot desired, skin layer element 36 d can be added in a step insertedsomewhere between steps 5 and 9 in the process flow of FIGS. 4A-4K, andthen heated- and cold-pressed with other elements when forming upperunibody shell 116.

In step 14 (FIG. 5D), a foam element 140 with attached collar element141 is placed onto a second jig 151 by inserting holes 152 a through 152i over corresponding pins 153 a through 153 i on jig 151. Collar element141 forms a lip that overhangs an upper edge of foam element 140. Insome embodiments, collar element 141 can be formed from a folded-oversection of material having an inverted “U” cross-section, with one legof that “U” attached to the inside upper edge of foam element 140 andthe other leg overhanging foam element 140 on the outside of that upperedge. Materials for foam element 140 can include open cell PU foam, andmaterials for collar element 141 can include synthetic suede. In step 15(FIG. 5E), edge 134 of unibody upper shell 116 (see FIG. 5A) is insertedunder the lip of collar element 141. In step 16 (FIG. 5F), a copper HFwelding tool (not shown) having a shape corresponding to collar element141 (or to a portion of collar element 141) is pressed onto collarelement 141 and heat applied (at a temperature, pressure and timeappropriate for the materials in use), thereby bonding shell 116, foamelement 140 and collar element 141 along the HF weld 153.

In step 17 (FIG. 5G), regions of unibody upper shell 116 adjacent edges133 and 135 (see FIG. 5A) are joined to transform shell 116 into athree-dimensional upper shape. Prior to step 17, extension tabs oncollar 141 and excess portions of foam element 140 are trimmed As partof step 17, the portion of panel 16 that includes edge 135 is placedinto a jig 160 having rails 161 and 162 that conform to the shape ofpanel 16 along edges adjacent to edge 135 and that hold shell 116 inplace. The remainder of shell 116 (with attached foam element 140 andcollar 141) is then wrapped under and around the reverse side of jig 160so as to place edge 133 over edge 135. An HF welding tool (e.g., formedfrom copper or other conductive material) having a shape correspondingto the overlapped portions adjacent edges 133 and 135 is pressed ontofolded-over panel 17 and heat applied (at a temperature, pressure andtime appropriate for the materials in use), thereby bonding regions ofshell 116 adjacent edges 133 and 135 along the HF weld 163.

After completion of step 17, the three-dimensional shell 116 (withattached collar 141 and foam element 140) may undergo additionalfinishing prior to bonding to midsole 42 (FIGS. 1A and 1B). In someembodiments, the toe portion of mesh composite panel 16 is heated andapplied to a shaping form so as to obtain a desired toe region shape. Insome embodiments, the toe portion of the three-dimensional shell isheated to approximately 80° C. for approximately 20 seconds. The heatedtoe portion is then pressed onto a shaping die to obtain the proper toeshape, with vamp gathering then performed during a cooling step atapproximately −4° C. for approximately 30 seconds. A plastic counter maybe inserted between foxing panel 17 and foam 140 in the heel region andstitched or otherwise fastened in place. The tongue and/or a bootie orother type of liner is attached, and upper 11 is completed by stitchinga Strobel in place around the lower edges of the upper panel while theupper is on a last.

Operations similar to those described above can be used to create atongue for attachment to shell 116. In particular, a tongue can also beformed by positioning one or more layers on jig, tacking those layerstogether, and then hot and cold pressing those layers to form a meshcomposite panel in the shape of a tongue. The mesh composite of thetongue can have similar materials as are described above (e.g., asubstrate, mesh and skin layers) or other combinations of materials. Forexample, a tongue composite panel can be formed to include a curvedcomposite panel shaped to conform to the top of a wearer's foot and/orto include a padded element that is molded into a desired shape on theouter (or inner) side of the tongue composite. Elements for such atongue composite could include a textile layer and a moldable foampadding layer. Instead of a using a set of flat press platens such as isshown in FIGS. 4J and 4K, a pair of curved platens can be used toachieve the desired curvature for the tongue. One of those curvedplatens could further include a mold cavity that is used to form thepadded element into the desired shape.

Additional Embodiments

Shoe 10 and the fabrication operations described above are merelyexamples of shoes and fabrication processes according to variousembodiments. As indicated above, the shape and arrangement of asubstrate layer, mesh layer and/or skin layer can vary in differentembodiments, as can the number, size and arrangement of ventilationopenings in a substrate. Moreover, different types of substratematerials, mesh materials and/or skin materials could be employed fordifferent shoe types. For example, a running shoe may utilize a meshmaterial that is lighter and/or has a different weave pattern than amesh material used for a basketball shoe. Indeed, a single shoe couldinclude more than one type substrate material and/or more than one typeof mesh material and/or more than one type of skin material. In someembodiments, a skin layer might be omitted.

Certain embodiments may incorporate more than one type of mesh materialin a single upper in various ways. For example, an upper according tosome such embodiments may have a first type of mesh material in oneportion of the upper and a second type of mesh material in a differentportion. The first type of mesh may be of lighter weight and have largeropenings so as to increase ventilation, and may placed in locations thatwill correspond to portions of an upper that will be subject to lesssevere forces. The second type of mesh material may have a denser weaveand/or be formed from a higher strength material, and may placed inlocations that will correspond to portions of an upper that will besubject to more severe forces. More than two types of mesh material canbe used in an upper, and different mesh material types can be combinedfor other reasons (e.g., to achieve a desired aesthetic, to reduce unitcost, etc.).

Some embodiments can include uppers in which there may be multiple meshlayers. In some cases, one mesh material panel may overlap another meshmaterial panel in an area where extra reinforcement is desired. In stillother cases, separate mesh material panels may not overlap one another,and may be located at different layers of an upper. For example, a firstpanel of mesh material could be overlaid on a substrate material layer,a second panel of substrate material (or other type of material)overlaid onto a portion of the first panel, and a third panel of meshmaterial overlaid so as to overlap a portion of the second panel. Insome embodiments, mesh material panels may be located at the same layerbut not overlap one another.

Additional types of materials can be added to an upper shell inadditional embodiments. Such additional materials can be included so asto form an outrigger, a shank, a heel cup, a toe cap, etc. For example,a panel of rigid nylon or other polymer could be included in the toeregion of a composite panel and shaped as part of the toe shapingprocess described above. As another example, a counter panel formed fromnylon or other type(s) of polymer could be included, during the processof assembling upper panels on an assembly jig, in a location thatcorresponds to the sides and rear of a wearer's heel in a completedshoe. Those counter panels can then be hot melt bonded to the inner sideof panel 17 during the pressing operations.

FIGS. 6A and 6B show examples of composite upper panel portions,according to some additional embodiments, that include an additionallayer for reinforcement, support and/or padding, dimensional stability,etc. In FIG. 6A, a layer 201 of additional material is interposedbetween a layer 28′ of mesh material and a layer 36′ of skin material.The material of layer 201 is bonded to the skin material of layer 36′and to the layer of mesh material 28′ with interposed layers of hot meltbonding material (not shown). In FIG. 6B, a layer 202 of additionalmaterial is located on an inner side of a substrate layer 27″ and bondedto that substrate layer with an interposed layer of hot melt bondingmaterial (not shown). Material in layer 201 or in layer 202 could be thesame material used in a substrate layer, could be a foam paddingmaterial, could be a plastic material that is rigid or semi-rigid, couldbe a rubber-like material, or could be a different type of material.Also shown in FIG. 6B are a mesh material layer 28″ and a skin materiallayer 36″. Examples of other materials that could be used for layer 201or 202 to provide reinforcement and/or support include (but are notlimited to) materials previously described herein and combinationsthereof. Other materials that permit sufficient inter-layer bonding,have limited stretch and have appropriate heat-setting properties canalso be used. Multiple layers of additional materials such as are shownfor layers 201 and 202 and/or combinations of materials (e.g., a foampanel and a rubber panel) could be employed. A composite panel having aconstruction such as indicated in FIGS. 6A and 6B, as well as othertypes of composite panels having added reinforcement/support materials,can be fabricated using assembly, tacking and hot/cold pressingoperations similar to those described herein.

In some embodiments, an upper shell formed according to the abovedescribed steps can include extensions in one or more panels (e.g.,panel 17 of FIGS. 4A1 et seq.) near regions that will correspond to theheel of a wearer. After completion of step 17 (FIG. 5G), the extensionscan then be wrapped around the bottom of the heel region to form adouble-lasted heel cup.

In certain embodiments, additional panels and/or panels havingextensions can be included in a panel assembly so as to form a carrierlayer for a foam inserts. For example, such extensions can be includedin regions of substrate material panels, foxing panels or other panelsthat can be wrapped under the bottom of a three-dimensional upper (afterstep 17 of FIG. 5G) so as to form a shelf for inclusion of foam paddingthat will cushion the bottom of a wearer's foot. Various types of foammaterials can be used in these and other embodiments, including but notlimited to foam materials as described in commonly-owned U.S. patentapplication Ser. No. 11/752,348, filed May 23, 2007, and incorporated byreference herein. One example of a shoe comprising a double-lasted upperthat forms a shelf for foam padding is described below in connectionwith FIGS. 10A through 16.

In some embodiments, and as shown in FIG. 7, a sole can include a toecap extension 203. As indicated above, mesh material 28 can be omittedfrom the composite portion of a panel that corresponds to the regionover which toe cap 203 will be located, thereby providing a smoothsurface onto which toe cap 203 could be bonded. Alternatively (oradditionally), a reinforcing stitch 204 can be included to secure toecap 203 in place. In still other embodiments, a toe cap can be formed byadding an additional layer of substrate material, a relatively thicklayer of abrasion resistant plastic (e.g., polyurethane), or othermaterial in the region that will correspond to the toe of the finishedupper. In some such embodiments, mesh material is omitted in the toeregion similar to the embodiment described in connection with FIGS. 4A1through 5G, while in other embodiments the mesh material may extend overthe entire toe region. In a similar manner, an additional layer ofsubstrate material, a relatively thick layer of abrasion resistantplastic (e.g., polyurethane), a shock absorbing material (e.g., Phylon(compressed ethylene vinyl acetate foam)) or other material can beincluded in regions of an upper that will correspond to the lower heeland/or edges of a wearer foot in a finished shoe.

In at least some embodiments mesh material can also be omitted fromportions of a composite panel that correspond to the regions where theupper will join a midsole. In this manner, a smoother transition fromupper to midsole or other tooling can be achieved. Alternatively, alayer of foam or other moderator can be interposed between the loweredge of an upper and a midsole.

In some embodiments, a substrate material panel can be pre-processed soas to create an indentation in the form of a product name, a logo, orother shape. A skin layer material panel is then placed over thesubstrate material panel so as to completely cover the indentation andcan be melted during the hot pressing operation so as to flow into andcompletely cover the indentation. The indentation can be created duringa pre-processing operation using an HF welding tool having the desiredshape, using laser cutting, or by other desired method. In certainembodiments, the skin layer panel used to cover the indentation may bethinner than skin layer panels used in other portions of an upper so asto create crisper and more defined edges of the covered indentation.Indentations can similarly be added to substrate material panels forother purposes. For example, indentations can be created to locateand/or accommodate harder materials used for reinforcement andprotection in certain regions (e.g., for eye stay reinforcement, forheel counters, etc.). As another example, indentations can be created tolocate and/or accommodate padding layers.

In certain embodiments, and as shown in FIG. 8, a layer of skin materialis used to reinforce the transition from the mesh composite portion of ashell to another portion. FIG. 8 is a cross-section taken from thelocation shown in FIG. 1A. As seen in FIG. 8, the skin material of panel36 a extends over foxing panel 17.

In some embodiments, malleoulus padding can be included in the region ofthe upper that will correspond to the portion of the wearer foot nearthe ankle. In some such embodiments, indentations are formed in theportions of foxing panel 17 (see FIGS. 4A1 et seq.) that will correspondto the regions around the wearer ankles. These indentations can beformed, after step 11 of FIG. 4K, using an HF welding element in theshape of the desired padding. That element is applied to the inner sideof panel 17, in the area that will correspond to the desired paddinglocation, so as to create a pocket to contain the padding. Applicationof the HF element will also deform the outer side of foxing panel 17 inthe shape of the padding element, thereby allowing the padding presenceto be visible in the finished upper. After creation of the paddingpocket, the padding elements can be glued in place in the pockets, andan inner lining element of artificial suede applied over the inner sideof the foxing panel to cover the padding elements. In some suchembodiments, the padding element 140 (and steps 14-16 of FIGS. 5Dthrough 5F) are omitted.

Various modifications can also be made to the above-describedfabrication process in other embodiments. For example, different typesof jigs or jig configurations can be used. In some embodiments, a jigwith retractable pins can be employed to eliminate the need for atacking operation (such as step 9 described above in connection withFIG. 4I). In some such embodiments, a heat-conductive jig withretractable pins is used to assemble elements of a shell and then placedface up onto a press having a heat-conductive silicone pad on an upperplaten. Techniques other than pins can also be used to hold shellelements during assembly (e.g., a vacuum table, a static charge system,etc.).

In some embodiments, a dual pan assembly jig can be employed so as toavoid a tacking step. FIGS. 9A through 9C show use of a dual pan jig 450according to some such embodiments. Jig 450 includes a lower pan 452 andan upper pan 453. Upper pan 453 includes a planar work surface 455surrounded by a raised rim 456. Surface 455 includes a collection ofthrough-holes, which holes are not visible in FIG. 9A, but which havelocations corresponding to pins 454. Surface 455 may have also have anon-stick coating. Pins 454, which are used to locate material panels ofa panel assembly 316, are affixed to lower pan 452 and protrude throughthe holes in surface 455. So as to avoid confusing the drawings, all ofpins 454 are not labeled. Lower pan 452 can be clipped or otherwiseaffixed to a planar work stand 451, with work stand 451 bolted orotherwise attached to a bench or other work location. For simplicity,panel assembly 316 is only shown generally in FIG. 9A. However, assembly316 could be identical to assembly 116 described above (with pins 454having relative locations identical to those of pins 101 a-101 qdescribed above). The details of a panel assembly and pin layout willdepend on a specific shoe design. In some embodiments, after a panelassembly layout pattern is developed for a specific upper, pins 454 arewelded, soldered or braised to lower pan 452 in an appropriate pattern,and corresponding holes drilled in upper pan 453.

Material panels of assembly 316 are placed in their proper locations onpins 454 in a manner similar to that described above in connection withFIGS. 4A1 through 4H, with the locations for individual panelsidentified by different groups of pins 454. If surface 455 does not havea non-stick coating, a layer of release paper can be placed onto surface455 before placing panels of assembly 316. Instead of tacking the panelstogether as described in connection with FIG. 4I, a silicone pad 420 isplaced over panel assembly 316 (FIG. 9B). Panel 420 is similar to panel120 describe above. Panel 420 has a shape that fits within rim 456 andis sufficiently thick to extend above rim 456.

While pad 420 rests over panel assembly 316, and as shown in FIG. 9C,upper pan 453 is pulled up and away from lower pan 452. Because pins 454(FIG. 9A) are attached to lower pan 452, those pins remain on pan 452 asupper pan 453 is moved away. The weight of pad 420 on assembly 316maintains the positions of the individual panels of assembly 316 onsurface 455 of pan 453, and thus a tacking operation can be omitted.Upper pan 453 (with assembly 316 and pad 420) can then be placed betweenheated press platens and hot pressing performed. In some embodiments,hot pressing time and/or press platen temperatures can be increased toaccount for heat absorption by pan 453. Pad 420 can be preheated priorto placement on upper pan 453. After hot pressing of assembly 316 in pan453, assembly 316 can be removed from pan 453 and cold pressingperformed, as described in connection with FIG. 4K, with a separate roomtemperature pad similar to pad 129 described above.

In some embodiments, an assembly process using jig 450 can be modifiedso that some or all of the assembled panels are slightly tacky. Thistackiness could prevent panels from slipping if pad 420 is moved afterplacement onto pan 453, but would allow removal and repositioning ofpanels during the assembly process. Panel tackiness can be achieved,e.g., by including small amounts of uncured bonding material on somepanels. In still other embodiments, panel tackiness can be achieved byincluding heating elements on lower pan 452 that raise the temperatureof pan 453 enough begin the melting of hot melt bonding materials in apanel assembly (and to at least partially preheat upper pan 453 beforethe hot pressing operation).

The order of at least some steps can also be varied in some embodiments.In some embodiments, a tool used in an HF welding process (e.g., step 16described above in connection with FIG. 5F) can include surfaceprotrusions that emboss a manufacturer's logo or other indicia in thewelded region.

As indicated above, some embodiments include upper shells that haveextensions used for double-lasting and/or to provide a shelf to supportfoam padding. FIGS. 10A through 10E show assembly of individual materialpanels that will be used to create a one-piece, unibody upper shell forsuch an embodiment.

In FIG. 10A, a first panel 501 of substrate material is positioned on anassembly jig (not shown). For convenience, locating holes (such as holes104 b-104 q in FIG. 4C) and locating hole extension tabs are not shownin FIGS. 10A-10E. However, the presence of such holes (and tabs, in someembodiments) is understood. For example, the assembly operations ofFIGS. 10A through 10E can be carried out using an assembly jig such asjig 100 and the techniques described in connection with jig 100.Alternatively, the assembly operations of FIGS. 10A through 10E could becarried out using a dual-pan assembly jig such as jig 450 and thetechniques described in connection with jig 450. Other jigs andtechniques could also be used.

Panel 501 will form the inner layer of the upper shell being fabricated.Panel 501 can be formed, e.g., from a synthetic leather or othermaterial from Table 1. Face 502 of panel 501 is visible in FIG. 10A.Face 502 will be the outer face of panel 501 in a completed shoe (i.e.,face 502 will be oriented away from the shoe interior). In someembodiments, panel 501 may include a laminated layer of TPU or otherheat-activatable bonding material on face 502. Unlike substrate panel 27(FIG. 4C) described in connection with a previous embodiment, panel 501will extend completely around a wearer foot in the completed shoe. Forexample, and as will be seen more clearly in connection with FIGS.12-14, the flat unibody upper shell of which panel 501 will form a partdoes not include a separate foxing panel in the hindfoot region.Instead, panel 501 is a contiguous piece of substrate material. In acompleted upper shell (and in the upper of the completed shoe includingthat shell), panel 501 includes portions located in lateral forefoot,lateral midfoot, top forefoot, medial forefoot, medial midfoot andhindfoot regions of the upper. The toe region of panel 501 includes acutout 505 that will accommodate a toe cap.

As previously discussed, a wide variety of ventilation openings can beincluded in upper shells according to various embodiments. For example,instead of relatively large ventilation openings such as holes 31-34 inupper 11 of shoe 10 (see, e.g., FIGS. 1A, 1B and 4C), panel 501 includesa plurality of smaller ventilation holes 503. As another example, otherembodiments could include large ventilation openings or a combination oflarge and small ventilation openings. Similarly, one or more ventilationopenings in top forefoot region 504 could be included.

In FIG. 10B, two mesh material panels 520 and 521 are placed ontosubstrate panel 501 so as to cover the ventilation holes 503 and theareas of panel 501 that surround holes 503. Panels 520 and 521 can,e.g., be cut from one of the materials identified in connection withTable 2 or otherwise identified as a possible mesh material inconnection with other embodiments. In some embodiments (e.g., wherepanel 501 does not include a layer of TPU or other bonding material onface 502), a separate layer of hot melt bonding material can beinterposed between substrate panel 501 and each of mesh material panels520 and 521.

In FIG. 10C, a first skin material panel 524 is placed over mesh panels520 and 521 and the region in between panels 520 and 521. Panel 524 alsoextends over much of the forefoot region of substrate panel 501. Panel524, e.g., can be cut from a sheet of one of the possible skin materialspreviously mentioned in connection with other embodiments. In someembodiments, that material may include a first layer formed from a TPUwith a lower melting point and a second layer formed from a highermelting point TPU or from PU, with the first layer oriented toward face502 of panel 501.

In FIG. 10D, reinforcement panels 527 and 528 are put into place. Panels527 and 528 are in some embodiments cut from the same synthetic leathermaterial used for panel 501. In other embodiments, panels 527 and 528may be cut from materials that differ from the material of panel 501(e.g., a different type of synthetic leather). Panels 527 and 528 neednot be cut from the same type of material. For example, panel 527 couldbe cut from a first material and panel 528 could be cut from a secondmaterial, with that first material being different from that secondmaterial.

In the completed shoe, panel 528 will surround the rear of the wearerfoot and includes an extension 506 that will extend over the lateralside of a wearer midfoot. Panel 528 further includes medial extension507 that will surround an ankle opening on a medial side and a lateralextension 508 that will surround an ankle opening on a lateral side.Extensions 507 and 508 respectively include cutouts 509 and 510 thatwill ultimately create decorative contours in the exposed surface of acompleted upper. Additional cutouts could be included in either or bothof extensions 507 and 508 and/or in other portions of panel 528.

Panel 527 will extend over the arch region or a wearer foot in acompleted shoe. Panels 529 and 530, which may be formed from nylon orother material, will serve as eye stay reinforcements in the completedshoe. The material(s) from which panels 527 and 528 are cut may includea laminated layer of TPU or other heat-activatable bonding material,which layer may then be oriented inward (e.g., toward face 502 of panel501). A separate layer of hot-melt bonding material can be placedbetween skin panel 524 and each of eye stay reinforcement panels 529 and530.

In FIG. 10E, three additional skin material panels 532-534 have beenplaced into position. As with panel 524, panels 532-534 can, e.g., becut from a sheet of one of the possible skin materials previouslymentioned in connection with other embodiments. As indicated above, thatskin material can include a first layer formed from a TPU with a lowermelting point and a second layer formed from a higher melting point TPUor from PU. The first layer of panels 532-533 could then be orientedinward, i.e., facing previously-placed panels. Panels 532-534 need notbe cut from the same type of skin material. For example, panel 532 couldcut from a first skin material, panel 533 cut from a second skinmaterial, and panel 534 cut from a third skin material, with each ofthose first, second and third skin materials being different from oneanother.

The assembly of panels from FIG. 10E is then subjected to hot and coldpressing as described above in connection with previous embodiments. Atconclusion of these pressing steps, the panel assembly from FIG. 10E isconverted into a bonded composite panel 540 as shown in FIG. 11. As inpreviously-described embodiments, these pressing operations cause skinpanels 532-534 conform to underlying elements. As a result, outlines 551and 552 of panels 527 and 528, respectively, are visible in skin panels534 and 532, respectively. In a similar manner, the outlines 553 and 554of eye stay reinforcing elements 529 and 530 are visible in skin panel533. The patterns of mesh panels 520 and 521 are partially visible inregions 559 and 560 of skin panel 524.

FIG. 12 shows composite panel 540 after trimming. In particular,peripheral edges of panel 540 have been trimmed in multiple locations soas to provide an even edge and to remove excess material. A tongueopening 565 has been cut, and material has been removed so as to freethe top and forward edges of lateral ankle tab 566. Lace eyelets 567have been punched through panel 540 along the edges of tongue opening565. Additional eyelets 568 have been punched through lateral ankle tab566 and medial ankle tab 570.

FIG. 13 shows the inner face 600 of substrate panel 501 (and of trimmedcomposite panel 540). Regions 601 a-601 k on inner face 600 arerespectively located adjacent to corresponding peripheral edge portions602 a-602 k. In a three-dimensional upper shell formed from shell 540,and as seen in connection with FIG. 15A, regions 601 a-601 k will bepart of extensions in a lower portion of that shell. As described belowin connection with FIGS. 15A and 15B, the extension regions 601 a-601 kare bonded to a lower surface of a foam midsole in a later step.

Also marked in FIG. 13 is a region 571 of inner face 600. In the nextstep of forming an upper that will include panel 540, region 571 isbonded to region 572 on the outer face of panel 540 (FIG. 12). Inparticular, and in the embodiments described in connection with FIGS.10A-16, trimmed panel 540 is a flat, unibody upper shell. Unlike certainpreviously-described embodiments, this flat unibody upper shell does notinclude a separate foxing panel in the hindfoot region. Regions 571 and572 can be bonded by interposing hot melt bonding material betweenregions 571 and 572, by placing those regions into contact with oneanother, and by then applying pressure and heat. A jig similar to jig160 (FIG. 5G) could be used.

In some embodiments, an ankle collar and/or padding can be added topanel 540 after trimming, but prior to bonding regions 571 and 572. Theankle collar (which could be located along edge 575 of panel 540) andthe padding (which could be part of the ankle collar and/or located onthe inside face of panel 540 below edge 575) could be added usingtechniques described in connection with previous embodiments.

FIG. 14 shows panel 540 after regions 571 and 572 have been bonded so asto convert panel 540 from a flat, unibody upper shell into athree-dimensional upper shell 540′. FIG. 14 further shows shell 540′placed onto a last L. Only a toe portion of last L and a last supportingbracket B are visible in FIG. 14. For simplicity, FIG. 14 does not showan ankle collar or features that could have been added in the hindfootregion of the shell 540′ prior to placing of shell 540′ onto last L. Insome embodiments, shell 540′ may undergo additional finishing prior toplacement onto last L. For example, shell 540′ could be heated andapplied to a shaping form so as to obtain a desired shape in certainregions.

Also shown in FIG. 14 is a foam midsole 610. The top side of midsole 610is shown in FIG. 14. Stated differently, the side of midsole 14 seen inFIG. 14 will face toward a wearer foot in a completed shoe. In theembodiment of FIGS. 10A-16, midsole 610 is formed from one or more foammaterials such as are described in the aforementioned U.S. patentapplication Ser. No. 11/752,348. Midsole 610 includes a top surface 611that is approximately contoured to conform to a wearer foot, as well asan edge wall 612 extends above surface 611 and that surrounds the sidesof a wearer foot to provide sideways support.

As part of assembling the shoe that will include shell 540′ and midsole610, midsole 610 is placed into shell 540′ so that surface 611 contactslast L. This is represented by an arrow in FIG. 14. FIG. 15A showsmidsole 610 after placement into shell 540′ and onto last L. In FIG.15A, the bottom surface 615 of midsole 610 is visible. The lowerportions of shell 540′ (including regions 601 a-601 k of inner face 600and corresponding peripheral edge portions 602 a-602 k) extend beyondbottom surface 615. These extension portions of shell 540′ form a skirtthat extends out of the plane of FIG. 15A.

In a subsequent fabrication step, the extension portions of shell 540′are folded over and bonded to surface 615. In particular, an adhesive isapplied to regions 601 a-601 k of inner face 600. A fabricator thensequentially pulls on lower portions of shell 540′ so as to stretchshell 540′ tightly against last L and, while maintaining tension onshell 540′, presses those pulled lower portions against surface 615 soas to bond each of regions 601 a-601 k to surface 615.

FIG. 15B shows midsole 610 after the lower portions of shell 540′ havebeen bonded to surface 615. Regions 601 b through 601 j become part of ashelf that supports midsole 610, and is located in a heel region.Regions 601 b through 601 j also form a double-lasted heel cup. Region601 a becomes part of the shelf supporting midsole 610 and is located inmedial mid- and forefoot regions. Region 601 k becomes part of the shelfsupporting midsole 610 and is located in lateral mid- and forefootregions.

In other embodiments, extension portions of an upper shell may not forma support shelf located in heel, medial mid- and forefoot, and lateralmid- and forefoot regions. For example, a shell in some embodiments mayonly include extensions that form a support shelf located in a heelregion. As another example, a shell in other embodiments may onlyinclude extensions that form a support shelf located in heel and midfootregions.

Ridge 616 extends above surface 615 and is used to position additionalsole structure elements in subsequent steps. Ridge 616 also compensatesfor the thickness of the shell 540′ portions bonded to surface 615. Inparticular, ridge 616 provides additional support in the central portionof the midsole 610 bottom surface that lack the presence of folded overshell 540′ portions.

FIG. 16 shows a shoe 700 that includes shell 540′ and bonded midsole 610from FIG. 15B. In subsequent fabrication operations, a toe cap 630 isattached by adhesively bonding the outer edges of shell 540′ near cutout505 to inner edges of toe cap 630. A support plate 631 and outsole 632are also attached. A tongue is attached to the interior of shell 540′,and an insole may be inserted. A bootie or other liner may also beattached, which liner may be a part of the tongue and attached as partof tongue attachment, and which liner may contain the insole. FIG. 16also shows an ankle collar 635 that has been added to shell 540′

In other embodiments that include upper shells with extensions used fordouble-lasting and/or to otherwise provide a shelf to support foampadding, numerous variations are possible. For example, fewer or morereinforcing panels can be used. The thicknesses, shapes, arrangementsand other aspects of such reinforcing panels can be varied. Decorativefeatures similar to those resulting from cutouts 509 and 510 can beachieved in additional ways. As but one example, a reinforcing panel canhave reduced thickness in a certain area instead of a slot cut all theway through the panel. As another example, a small piece of material(e.g., in the shape of a logo) could be placed on an outer surface of areinforcing panel so as to create an outline when skin material is laterbonded to the reinforcing panel.

A bonded mesh composite panel used in an upper of a shoe such as that ofFIGS. 1A and 1B (or of FIG. 16) offers numerous advantages. Thecomposite panel includes substrate material in regions where support andprotection for the wearer's foot is helpful, but can include relativelylarge openings in other areas. These openings help to reduce weight andto facilitate ventilation of the shoe interior. The mesh materialprovides tensile strength to bridge openings in the substrate layer andto augment the strength of the substrate layer in other areas. Bybonding the mesh layer to the substrate layer over a wide area, seamsalong edges of the substrate ventilation openings can be avoided,thereby reducing the likelihood of tearing or separation along thoseventilation hole edges. The skin layers can be used to provide abrasionresistance in various areas and/or to achieve desired aesthetic effects.

The above described fabrication processes for creating a bonded meshcomposite panel also offer numerous advantages. Using theabove-described processes, a relatively complex composite can be quicklyformed in a simple manner using relatively simple equipment. Moreover,the above-described processes can also facilitate inexpensive changes toa composite panel design (for either functional or aesthetic reasons)without requiring substantial expensive re-tooling.

The foregoing description of embodiments has been presented for purposesof illustration and description. The foregoing description is notintended to be exhaustive or to limit embodiments of the presentinvention to the precise form disclosed, and modifications andvariations are possible in light of the above teachings or may beacquired from practice of various embodiments. As but one example,techniques such as are described herein can be used to fabricatearticles other than footwear uppers. The embodiments discussed hereinwere chosen and described in order to explain the principles and thenature of various embodiments and their practical application to enableone skilled in the art to utilize the present invention in variousembodiments and with various modifications as are suited to theparticular use contemplated. Any and all permutations of features fromabove-described embodiments are the within the scope of the invention.

1. An article of footwear comprising: an upper having a bonded meshcomposite panel, wherein a portion of the composite panel includes asubstrate layer formed from a substrate material, the substrate layerhaving an inner side facing toward an interior of the article and anouter side facing away from the interior, the composite panel furtherincludes a mesh layer formed from a mesh material, a portion of the meshlayer overlapping the substrate layer in one or more mesh/substrateoverlap areas, the mesh layer having an inner side oriented toward thesubstrate layer outer side within the mesh/substrate overlap areas, andthe composite panel further includes a skin layer formed from a skinmaterial, a portion of the skin layer overlapping both the mesh and thesubstrate layers in one or more skin/mesh/substrate overlap areas, theskin layer having an inner side oriented toward the mesh and substratelayers within the skin/mesh/substrate overlap areas; and a foam midsolebonded to the composite panel, wherein the composite panel includesportions bonded to a bottom surface of the foam midsole.
 2. The articleof footwear of claim 1, wherein the composite panel portions bonded to abottom surface of the foam midsole include portions surrounding a heelregion of the foam midsole so as to form a double lasted heel cup. 3.The article of footwear of claim 1, wherein the composite panel portionsbonded to a bottom surface of the foam midsole form a shelf to supportthe foam midsole and are bonded to the midsole in heel and midfootregions.
 4. The article of footwear of claim 1, wherein the compositepanel portions bonded to a bottom surface of the foam midsole form ashelf to support the foam midsole and are bonded to the midsole in heel,midfoot and forefoot regions.
 5. The article of footwear of claim 1,wherein the composite panel includes at least one reinforcement panelbonded to the outer side of the substrate layer.
 6. The article offootwear of claim 5, wherein the reinforcement panel and the substratelayer are formed from artificial leather.
 7. The article of footwear ofclaim 5, wherein the skin layer includes an element in a region at leastpartially overlapping the reinforcement panel and revealing a contour ofthe reinforcement panel.
 8. The article of footwear of claim 1, whereinthe substrate layer includes a contiguous piece of substrate materialhaving portions located in lateral forefoot, lateral midfoot, topforefoot, medial forefoot, medial midfoot and hindfoot regions of theupper.
 9. The article of footwear of claim 1, wherein a portion of themesh layer covers open areas in which no substrate material is present.10. The article of footwear of claim 1, wherein the skin layer includesan outer side revealing a texture corresponding to the mesh layer.
 11. Amethod of fabricating an article of footwear, comprising: positioning aplurality of panels into an assembly, wherein the assembly includes asubstrate material panel having a first side and a second side, a meshmaterial panel having a first side facing away from the substratematerial panel and a second side facing the substrate material panel, atleast a portion of the mesh material panel overlapping the substratematerial panel in a mesh/substrate overlap area, and a skin materialpanel having a first side facing away from the substrate material paneland a second side facing the substrate material panel, at least aportion of the skin material panel overlapping both the substratematerial panel and the mesh material panel in a skin/mesh/substrateoverlap area; creating a bonded mesh composite panel by compressing theassembly at a first temperature in a first pressing operation duringwhich the first sides of the substrate material, mesh material and skinmaterial panels face a compressible surface conforming to the assembly,and compressing the assembly at a second temperature in a secondpressing operation during which the first sides of the substratematerial, mesh material and skin material panels face a compressiblesurface conforming to the assembly, wherein the second pressingoperation is performed after the first pressing operation and the secondtemperature is lower than the first temperature; subsequent to thesecond pressing operation, forming a three-dimensional upper shell fromthe composite panel; and bonding portions of the three-dimensional uppershell to a bottom surface of a foam midsole.
 12. The method of clam 11,wherein bonding portions of the three-dimensional upper shell comprisesbonding portions of the upper shell to surfaces of a heel region of thefoam midsole so as to form a double lasted heel cup.
 13. The method ofclaim 11, wherein bonding portions of the three-dimensional upper shellcomprises bonding portions of the upper shell to surfaces of the foammidsole so as to form a shelf, wherein the shelf is located in heel andmidfoot regions.
 14. The method of claim 13, wherein the shelf islocated in heel, midfoot and forefoot regions.
 15. The method of claim11, wherein the assembly includes at least one reinforcement panellocated on the first side of the substrate layer.
 16. The method claim15, wherein the reinforcement panel and the substrate layer are formedfrom artificial leather.
 17. The method of claim 11, wherein thesubstrate material panel comprises a contiguous piece of substratematerial having portions located in lateral forefoot, lateral midfoot,top forefoot, medial forefoot, medial midfoot and hindfoot regions atthe conclusion of the forming of the three-dimensional upper shell.